Method and apparatus for collating paper webs

ABSTRACT

A series of paper webs are directed upwardly from corresponding rolls and are each attached by marginal glue spots or lines or a series of crimps to a corresponding carbon or transfer web. The sets of paper and transfer webs are directed horizontally in vertical spaced relation to corresponding feed rollers having pins which engage marginal perforations within the paper webs and feed the web sets downwardly in overlapping relation into a pin conveyor. The feed rollers are arranged in closely spaced relation, and each feed roller is rotatably adjustable relative to the drive mechanism for the rollers. Marginal glue spots or lines are applied to the paper webs just ahead of the feed rollers, and the collected webs are impacted at the glue spots to secure the webs together.

United States Patent Schriber 1451 Aug. 8, 1972 METHOD AND APPARATUS FOR 2,788,208 4/1957 Pearce ..270/52 COLLATING PAPER WEBS 3,303,083 2/1967 Hedenstrom ..lS6/Sl3 [72] Inventor: Louis Schriber, Dayton, Ohio FOREIGN PATENTS OR APPLICATIONS [731 Assignee= fimis-lmertyile Corporation, 1,181,239 2/1959 France ..270/52 Cleveland, Ohio 22 Filed: July 15,1969 Z y g a gp g g g 21 Appl. 190.; 841,761 omey am rem [57] ABSTRACT [22] :LSg ..270/52 A Series of paper webs are directed upwardly from [5 .t ..B65h 39/16 corresponding rolls and are each attached y marginal 8] 0 3% 251 2 {2 glue spots or lines or a series of crimps to a cor- 15 I5 responding carbon or transfer web. The sets of paper 56 R t Cted and transfer webs are directed horizontally in vertical 1 e erences I spaced relation to corresponding feed rollers having UNTTED STATES PATENTS pins which engage marginal perforations within the paper webs and feed the web sets downwardly 1n over- 1670,787 5/ 1928 Sherman a1 "270/52 lapping relation into a pin conveyor. The feed rollers WOOd are arranged in closely paced relation and ea h feed 2,154,157 4/1939 Fulk ..270/52 roller is rotatably adjustable relative to the drive 2,209,691 7/1940 Fulk ..270/52 mechanism for the rollem Margina] glue spots or lines 2,859,035 11/1958 Fran2mann ..270/52 are applied to the paper webs j ahead of the feed rollers, and the collected webs are impacted at the u l th b t h 2,334,485 11/1943 Etfl ..l56/555 guesp we 8 oge er 2,358,928 9/1944 Huck ..270/32 16 Claims, 3 Drawing Figures PMENTEB 8 t972 ATTORNEYS METHOD AND APPARATUS FOR COLLATING PAPER WEBS BACKGROUND OF THE INVENTION In a collator for assembling a plurality of paper webs and carbon or transfer webs into continuous business forms, as for example, the collator generally disclosed in US. Pat. No. 3,303,083 which issued to the assignee of the present invention, it is common to arrange the paper supply rolls on horizontally spaced spindles and to direct the webs from the rolls upwardly around corresponding feed cylinders where the webs are collected in overlapping relation along a horizontal path. Each feed cylinder incorporates peripherally spaced outwardly projecting retractable pins which enter longitudinally spaced marginal perforations within the webs to assure registration and positive feeding of the assembled webs along a predetermined path through cross perforating rolls and then to a zig-zag folding machine.

In another fonn of collator, such as disclosed in US. Pat. No. 2,859,035, the paper and carbon rolls are supported above an endless pin conveyor, and the webs are directed downwardly to the conveyor which delivers the collected webs to a zig-zag folder. Preferably, however, the roll supporting spindles are located close to the floor as shown in US. Pat. No. 3,303,083 to facilitate loading of the rolls onto the spindles.

It has been found that due to stretching of some paper webs, the spacing of the marginal perforations will vary, as for example, up to 1/16 inch in ten feet. As a result, when the webs are collected along the path defined by the pin cylinders or on the endless pin conveyor, some pins will not engage the marginal perforations within the stretch webs and relative slip will occur between adjacent webs so that they are no longer in registration.

SUMMARY OF THE INVENTION The present invention is directed to an improved method of assembling webs and to improved collating apparatus wherein the carbon and paper roll support spindles are located relatively close to the floor as disclosed in above US. Pat. No. 3,303,083 so that the rolls can be conveniently loaded onto the spindles. The apparatus further provides for attaching a carbon web to each paper web and subsequently collecting the paper webs in overlapping relation within a distance of only a few feet so that the variation in the spacing of the marginal perforations in the different webs does not prevent the feed pins from entering the marginal perforations within the webs. The apparatus also provides for conveniently threading and registering the leading end portion of each web to minimize the time required for setting up the apparatus to assemble the webs from a new set of paper and carbon rolls.

In accordance with a preferred embodiment of the invention, the support spindles for the paper rolls are located in parallel spaced relation in a horizontal plane, and the support spindles for the carbon rolls are located directly above the support spindles for the paper rolls in a manner as shown in above US. Pat. No. 3,303,083. The webs from each set of paper and carbon rolls are directed upwardly and are secured together by either a crimping operation or marginal glue spots or lines. The sets of paper and carbon webs are directed horizontally in vertical spaced relation to a corresponding series of feed rollers from which the sets of carbon and paper webs are then directed downwardly to a horizontal surface and the upper coplanar runs of a plurality of endless pin conveyors.

The pin or feed rollers are arranged with their axes in closely spaced relation, as for example, at intervals of seven or eight inches so that a number of webs can be collected in overlapping relation on the pin conveyors within the distance of only a few feet. A loop is formed in each paper web between its corresponding feed or pin roller and the endless pin conveyor so that each web will smoothly roll onto the upper surface of the adjacent web. In addition, each feed roller is rotatably adjustable relative to the feed roller drive mechanism to provide for conveniently registering the webs prior to initial start up and for providing the desired loop in each web above the pin conveyor.

BRIEF DESCRIPTION OF THE DMWING FIG. 1 is a somewhat schematic elevational view of collating apparatus constructed in accordance with the invention;

FIG. 2 is an enlarged fragmentary elevational view of the web collecting portion of the apparatus shown in FIG. 1; and

FIG. 3 is an enlarged fragmentary section taken generally on the line 3-3 of FIG. 2.

DESCRIPTION OF THE PREFERRED EMBODIMENT The collating apparatus shown in FIG. 1 includes an elongated base 10 from which extends a vertical frame or wall 12. A series of horizontally arranged parallel spindles 14 are cantileveredly supported by the frame wall 12 for free rotation and receive corresponding rolls R of paper webs P each having longitudinally spaced marginal perforations or feed holes. In a conventional manner, each roll R is located or unwound by a surface engaging endless belt 15 supported by a pivoted frame and connected to a drive 16. Each belt 15 is driven slightly faster than the speed of the paper in the machine so that slightly more paper than necessary tends to feed into the machine.

Each paper web P is directed from its roll R around a tension or dancingrod 17 supported by a counterbalanced arm 18 having a pivot axis 19. A pneumatic brake 20 is mounted on the wall 12 under each of the spindles l4 and includes a brake shoe 21 which is adapted to engage the spindle 14. Each brake 20 also includes an actuator rod 22 which is pivotally connected to the corresponding arm 18 at a point close to the pivot axis 19. When the tension in one of the webs P begins to drop below a predetermined value, the corresponding dancer rod 17 moves downwardly and causes the corresponding brake shoe 21 to apply pressure against the corresponding spindle 14 so that the drive belt 15 slips a little on the surface of the roll. As a result, each paper web is fed at a constant feed rate from its corresponding roll depending on the demand from the machine.

A series of freely rotatable spindles 24 are cantileveredly supported by the wall 12 directed above the spindles 14 and support rolls R of carbon webs C which are narrower in width than the paper webs P so that the edges of the carbon webs will be spaced inwardly of the feed holes within the paper webs. Each of the rolls R is driven in a manner similar to the rolls R that is, by a surface engaging endless belt connected to the drive 16. Each carbon web C is directed from its roll R around a corresponding tension or dancing rod 26 which is supported in the same manner as each of the tension rods 17 and is effective to control a corresponding pneumatic brake 20 as described above for each of the spindles 14.

Each of the paper webs P is directed upwardly from the corresponding tension rod 17 around a driven roller 28 and then to a roller 30. Each carbon web C is directed upwardly from its tension rod 26 around a corresponding driven roller 28, then between snubbing rods 31 to join the corresponding paper web P under the adjacent roller 30. A glue applicator 32 is positioned adjacent each of the rollers except for the end roller, and includes a discharge nozzle 33 supported below a rotating brush 34 having angularly arranged groups of bristles.

The inner marginal edge portion of each paper web P is directed between the nozzle 33 and brush 34 of the corresponding glue applicator 32 to receive longitudinally spaced glue spots for securing the paper web P to the adjacent carbon web C at the roller 30. As an alternative to spot gluing, by using a brush with full bristles or by stopping the rotation of each brush 34 with one group of bristles located directly over the corresponding nozzle 33, a continuous line of glue is applied to the corresponding paper web P. Instead of gluing the marginal edge portions of each set of paper and carbon webs with the glue applicators 32, the edge portions of the webs may be secured together by longitudinally spaced crimps produced by the cooperation of circumferentially spaced projecting prongs on a crimping wheel 29 and circumferentially extending grooves within the adjacent roller 30.

The sets of attached paper and carbon webs P and C are directed generally horizontally from the rollers 30 by a series of cantileveredly supported guide rods 35 and axially adjustable collars 36 to a corresponding series of horizontally arranged feed rollers 40. The rollers 40 are mounted on parallel spaced shafts 41 cantileveredly supported by the wall 12 and driven at a common speed by a gear belt or chain drive 42 connnected to the main drive 16. Referring to FIG. 3, the outer end of each feed roller 40 is connected to the corresponding support shaft 41 by a clamping mechanism 45 which includes a ring 46 secured to the roller 40 by a series of screws 47. The ring 46 has an inwardly projecting lip 48 which retains an outwardly projecting flange 49 of a threaded sleeve 50 keyed to the outer end portion of the shaft 41.

A knob-like nut 52 is threaded onto the sleeve 50 and cooperates with the flange 49 and a friction washer 53 to clamp the lip 48 of the ring 46 to the shaft 41. By releasing the nut 52, the roller 40 may be freely rotated on the shaft 41. The inner end portion of each feed roller 40 has outwardly projecting peripherally spaced pins 55 which are preferably retractable by an internal cam (not shown) as the roller 40 rotates. While peripheral pins 55 are shown on only the inner end portion of each roller 40, it is to be understood that similar pins may also be provided on the outer end portion of each roller 40 if it is desired to engage feed holes in both marginal edge portions of each web as will be explained later.

Referring to FIG. 2, a series of endless pin conveyors are positioned in alignment below the feed rollers 40, and each conveyor 60 is directed around end drive sprockets 62 and 63 and an adjustable idler sprocket 64. The upper runs of the conveyors 60 extending between the sprockets 62 and 63, lie in a horizontal plane which is parallel to the plane define by the axis of the shafts 41 for the feed rollers 40. A table or platform 65 is supported forwardly of the pin conveyors 60 so that its upper surface is generally coplanar with the upper runs of the conveyors 60, but each of the conveyors 60 has longitudinally spaced pins 66 which project above the upper surface of the platform. Each of the sprockets 63 is connected to a collar 67 by a screw 68 extending through an arcuate slot formed within the sprocket 63 to provide for rotational adjustment of each sprocket 63 relative to its supporting shaft which is driven by a chain drive 70 connected to the main drive 16.

As mentioned above, each assembled set of paper and carbon webs are either crimped together by the corresponding crimping wheel 29 or glued together by the corresponding glue applicator 32. The web set is then directed to the corresponding feed roller 40 by one or more stationary guide rods 35 which maintain the web sets in vertically spaced relation. The adjustable collars 36 are mounted on some of the guide rods 35 to maintain alignment of the paper webs P between the rollers 30 and the feed rollers 40.

A glue applicator 32 is positioned adjacent each of the feed rollers 40 except for the inner roller 40, for adding fine marginal glue spots to paper webs P just ahead of the rollers 40. A reverse loop is formed within each of the sets of paper and carbon webs between the corresponding feed roller 40 and the upper run of the adjacent pin conveyor 60 so that the web sets roll smoothly onto each other in overlapping relation on top of the table 65 and the conveyors 60 where the webs are held down by pivotally supported idle rollers 76. The inner marginal edge portions of the assembled paper and carbon webs are fed by the conveyors 60 between a backup roller 77 and an impact roller 78 having peripherally spaced flats 79, and then through a set of cross perforation cylinders 80 to a zig-zag folding machine (not shown).

From the drawing and the above description, it is apparent that a collating apparatus or machine constructed in accordance with the invention provides desirable features and advantages. For example, the overall arrangement of the spindles 14 and 24 and the feed rollers 40 relative to the pin conveyors 60 not only provides for conveniently loading the paper and carbon rolls onto the spindles 14 and 24, respectively, but also enables the sets of paper and carbon webs to be collected and assembled in overlapping relation within a relatively short distance of only a few feet. Preferably, the distance between the axes of adjacent feed rollers 40 is less than one-half (approximately one-third) of the distance between the axes of the spindles l4 supporting the rolls R, from which the corresponding paper webs P extend. Thus the variation in the spacing between the marginal perforations within the different paper webs P does not prevent some of the webs from being engaged by the pins 66 on the conveyors 60 but enables the pins 66 to extend through the marginal perforations in all of the overlapping webs so that the webs are properly fed and maintained in precise registration.

For example, by arranging the feed rollers 40 in closely spaced relation with seven or eight inches between the axes of adjacent feed rollers 40, a substantial number of webs can be assembled within a length of four or five feet so that a variation in the marginal perforations of plus or minus 1/16 inch in ten feet would be equivalent to plus or minus 1/32 inch in five feet. The pins 66 on the conveyors can easily accept these variations and are assured of properly engaging the marginal perforations in all of the webs without tearing the perforations or causing some of the webs to ride on top of the pins of the conveyors.

Another important feature is provided by the release of the drive connection for each of the feed rollers 40 so that each feed roller 40 may be freely rotated relative to the chain drive 42. That is, by releasing the nuts 52, each of the paper webs can be conveniently advanced or retarded manually without the necessity of lifting the paper web from the pins on the corresponding roller 40, to obtain precise registration between the webs and to obtain the desired curvature of the loops 75 within the webs above the conveyors 60 so that the webs flow smoothly onto the upper runs of the pin conveyors 60. It is to be understood that instead of disengaging each roller 40 from its drive shaft 41, the free rotation of each roller 40 could be provided by disengaging each shaft 41 from the main drive 16.

Another important feature of the invention is obtained by employing a plurality of pin conveyors 60 rather than a single pin conveyor, by driving both end sprockets for each conveyor and by providing rotational adjustment of one of the drive sprockets relative to the main drive 16. That is, if one of the pin chain conveyors 60 begins to wear and stretch, one or more of the pin conveyor sprockets 63 can be adjusted relative to the corresponding driven conveyor sprockets 62 so that precise spacing can be maintained between the pins 66 on the upper runs of the conveyors 60 within the relatively short distance in which the webs W are collected or assembled in overlapping relation.

The glue applicators 32 and the impact roll 78 provide another important advantage. That is, the brushes 34 provide another important advantage. That is, the brushes 34 are rotated by a connection to the main drive 16 and in a direction so that the groups of bristles sweep against the movement of the webs. As a result, a marginal edge portion of each paper web P is depressed downwardly between spaced guide rods and against the corresponding nozzle 33 at longitudinally spaced intervals to apply fine glue spots on each web. The driven impacting wheels 77 and 78 are effective to compress the assembled webs at each glue spot. When it is desirable to have a continuous line of glue, for example in the assembling of snap-out business forms, the apparatus can be easily adapted by stopping the rotation of the brushes 34 or by replacing the brushes 34 with a full rotary brush without groups of bristles.

Still another advantage is provided by either spot gluing or crimping together the marginal edge portions of each set of carbon and paper webs with the corresponding crimping wheel 29 and roller 30 or glue applicator 32. This operation assures that each carbon web C is fed to the main collating area in precise alignment with its corresponding paper web P and also provides for conveniently separating the carbon webs or sheets after the forms have been later processed in a business machine. Furthermore, the gluing or crimping operation on each set of paper and carbon webs assures that the carbon webs will not be stretched tighter than the corresponding paper webs and will be substantially the same length over a given distance.

While the method hereindescribed, and the form of apparatus for carrying this method into efiect, constitute preferred embodiments of the invention, it is to be understood that the invention is not limited to this precise method and form of apparatus, and that changes maybe made in either without departing from the scope of the invention.

What is claimed is:

1. Improved collating apparatus for assembling a plurality of paper webs each having longitudinally spaced marginal perforations and extending from a roll, comprising a first group of a plurality of spaced spindles disposed generally horizontally for supporting the rolls, a plurality of feed members disposed in generally horizontally spaced relation from said spindles and supported for rotation on parallel axes spaced substantially closer to each other than said spindles, each said feed member including pins adapted to extend into the perforations of a corresponding web, means simultaneously driving said feed members, means for directing the webs from the rolls generally upwardly and then generally horizontally to said feed members, means maintaining the webs in spaced relation from the rolls to said feed members, conveyor means extending generally horizontally below said feed members and positioned to receive the webs in overlapping relation from said feed members, said conveyor means including pins adapted to extend into the aligned perforations of the overlapping webs, and means driving said conveyor means along with said feed members.

2. Apparatus as defined in claim 1 including a second group of a plurality of spindles located above said first group of spindles for supporting rolls of transfer webs, and means for securing each transfer web to one of the paper webs beforethe paper web is directed horizontally to the corresponding said feed roller.

3. Apparatus as defined in claim 2 wherein said securing means comprise a glue applicator ,for each transfer web, and each said glue applicator includes a rotary brush having angularly spaced groups of bristles to effect spot gluing of the webs.

4. Apparatus as defined in claim 2 wherein said securing means comprise a crimper wheel for each transfer web.

5. Apparatus as defined in claim 1 wherein said feed members are disposed within a plane extending substantially parallel to said conveyor means to provide for forming a loop within each web between the corresponding said feed member and said conveyor means.

6. Apparatus as defined in claim 1 wherein said conveyor means comprise at least one endless pin chain having an upper run positioned to receive the overlapping webs.

7. Apparatus as defined in claim 1 wherein said conveyor means comprise a plurality of endless conveyors having coplanar upper runs, each said conveyor having longitudinally spaced said pins, and means for adjustably advancing or retarding said pins of at least one of said conveyors relative to said drive means for said conveyor.

8. Apparatus as defined in claim 1 wherein the axes of said spindles define a first generally horizontal plane, said feed members are located in a second generally horizontal plane above said first plane, and said conveyor means is disposed to convey the assembled webs within a third generally horizontal plane located above said first plane and below said second plane.

9. Apparatus as defined in claim 1 wherein the distance between said feed members for adjacent webs is less than one-half the distance between said spindles supporting the rolls from which the webs extend.

10. Apparatus as defined in claim 1 wherein the distance between said feed members for adjacent webs is approximately one-third the distance between said spindles supporting the rolls from which the webs extend.

11. Apparatus as defined in claim 1 including a plurality of glue applicators each positioned .to apply glue to a marginal edge portion of a web in an area adjacent the corresponding feed member, and each said glue applicator includes a brush member positioned adjacent a nozzle.

12. An improved method of assembling a plurality of paper webs each having longitudinally spaced marginal perforations and extending from a roll, comprising the steps of arranging the rolls in horizontally spaced relation, directing the webs generally upwardly from said rolls and then generally horizontally to a corresponding plurality of horizontally arranged feed members having pins for extending into the perforations, maintaining the webs in spaced relation from the rolls to the feed members, directing the webs downwardly from the feed members to an upper run of a generally horizontally extending endless conveyor having pins for extending into the perforations, and collecting the webs in overlapping relation on the upper run of the conveyor.

13. A method as defined in claim 12 including the step of applying glue to a marginal edge portion of each web in an area adjacent the corresponding said feed roller.

14. A method as defined in claim 13 including the step of successively impacting the edge portions of the overlapping webs collected on said upper run of said conveyor.

15. A method as defined in claim 12 including the step of securing a carbon web to each of the paper webs before the paper web is directed generally horizontally to the corresponding said feed member.

16. A method as defined in claim 15, wherein the step of securing a carbon web to a paper web is accomplished by. crimping them together at spaced locations before the webs are collected on the conveyor. 

1. Improved collating apparatus for assembling a plurality of paper webs each having longitudinally spaced marginal perforations and extending from a roll, comprising a first group of a plurality of spaced spindles disposed generally horizontally for supporting the rolls, a plurality of feed members disposed in generally horizontally spaced relation from said spindles and supported for rotation on parallel axes spaced substantially closer to each other than said spindles, each said feed member including pins adapted to extend into the perforations of a corresponding web, means simultaneously driving said feed members, means for directing the webs from the rolls generally upwardly and then generally horizontally to said feed members, means maintaining the webs in spAced relation from the rolls to said feed members, conveyor means extending generally horizontally below said feed members and positioned to receive the webs in overlapping relation from said feed members, said conveyor means including pins adapted to extend into the aligned perforations of the overlapping webs, and means driving said conveyor means along with said feed members.
 2. Apparatus as defined in claim 1 including a second group of a plurality of spindles located above said first group of spindles for supporting rolls of transfer webs, and means for securing each transfer web to one of the paper webs before the paper web is directed horizontally to the corresponding said feed roller.
 3. Apparatus as defined in claim 2 wherein said securing means comprise a glue applicator for each transfer web, and each said glue applicator includes a rotary brush having angularly spaced groups of bristles to effect spot gluing of the webs.
 4. Apparatus as defined in claim 2 wherein said securing means comprise a crimper wheel for each transfer web.
 5. Apparatus as defined in claim 1 wherein said feed members are disposed within a plane extending substantially parallel to said conveyor means to provide for forming a loop within each web between the corresponding said feed member and said conveyor means.
 6. Apparatus as defined in claim 1 wherein said conveyor means comprise at least one endless pin chain having an upper run positioned to receive the overlapping webs.
 7. Apparatus as defined in claim 1 wherein said conveyor means comprise a plurality of endless conveyors having coplanar upper runs, each said conveyor having longitudinally spaced said pins, and means for adjustably advancing or retarding said pins of at least one of said conveyors relative to said drive means for said conveyor.
 8. Apparatus as defined in claim 1 wherein the axes of said spindles define a first generally horizontal plane, said feed members are located in a second generally horizontal plane above said first plane, and said conveyor means is disposed to convey the assembled webs within a third generally horizontal plane located above said first plane and below said second plane.
 9. Apparatus as defined in claim 1 wherein the distance between said feed members for adjacent webs is less than one-half the distance between said spindles supporting the rolls from which the webs extend.
 10. Apparatus as defined in claim 1 wherein the distance between said feed members for adjacent webs is approximately one-third the distance between said spindles supporting the rolls from which the webs extend.
 11. Apparatus as defined in claim 1 including a plurality of glue applicators each positioned to apply glue to a marginal edge portion of a web in an area adjacent the corresponding feed member, and each said glue applicator includes a brush member positioned adjacent a nozzle.
 12. An improved method of assembling a plurality of paper webs each having longitudinally spaced marginal perforations and extending from a roll, comprising the steps of arranging the rolls in horizontally spaced relation, directing the webs generally upwardly from said rolls and then generally horizontally to a corresponding plurality of horizontally arranged feed members having pins for extending into the perforations, maintaining the webs in spaced relation from the rolls to the feed members, directing the webs downwardly from the feed members to an upper run of a generally horizontally extending endless conveyor having pins for extending into the perforations, and collecting the webs in overlapping relation on the upper run of the conveyor.
 13. A method as defined in claim 12 including the step of applying glue to a marginal edge portion of each web in an area adjacent the corresponding said feed roller.
 14. A method as defined in claim 13 including the step of successively impacting the edge portions of the overlapping webs collected on said upper run of said conveyor.
 15. A method as defined In claim 12 including the step of securing a carbon web to each of the paper webs before the paper web is directed generally horizontally to the corresponding said feed member.
 16. A method as defined in claim 15, wherein the step of securing a carbon web to a paper web is accomplished by crimping them together at spaced locations before the webs are collected on the conveyor. 